So there was a video posted a while ago that showed a good simple way to rebuild these. His method works just fine.
He mentioned in his video that he didn't want to remove the top - something about others breaking or bending it or something. Well, I gave it try and it twists off pretty easily. Gripped it in one pair of pliers and twisted/pulled with the other. Easy peasy:
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The only real reason I wanted the top off was to keep the cotton inside the head and give me room to fluff out the cotton around the openings. Mission accomplished. I suppose if you wanted to try to build a BVC head out of this, this would make it much easier to do that.
This is the original coil. It is pretty tightly packed with cotton. It is a 3.5mm coil:
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I was shooting for 1Ω coil, so I used 26ga Kanthal, 5/4 wrap:
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I used the same method as the video for securing the coil and working in the cotton, but I cut the cotton flush with the outsides and then worked it inside and fluffed it out. Worked great:
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Been using it most of the day. Really good so far....